Optical fiber array with precise fiber positioning

Abstract

Optical fiber array apparatus comprising housing front mask having a matrix of fiber seating openings each opening having one or more side walls. An optical fiber extends through each opening and means presses the fiber side surface into engagement with the one or more side walls to precisely position and secure the fiber. Bonding material then fills all voids in and around the opeining. In one embodiment, a clamping wafer behind the front mask moves to clamp the fibers to the front mask opening walls. In another, the front mask defines flexing arms with distal ends that clamp fibers to opening walls and in yet another elongated flexible members lie along front mask slots to clamp fibers in openings that communicate into the slots.

What is claimed is:  
     
       1. An optical fiber array apparatus comprising 
       a housing,  
       a front mask coupled to said housing and having a matrix of fiber seating openings therethrough, each said opening having one or more stationary side walls,  
       an unsheathed optical fiber portion extending through each of said openings and having an outer cylindrical side surface,  
       means for pressing said side surface into engagement with said one or more side walls,  
       wherein said means comprises at least one movable arm defined by and attached to said front mask, and  
       each said arm having a contact portion that contacts said fiber for pressing said fiber against said one or more side walls, and the distance from said contact portion to the arm portion attached to a front mask portion being greater than the diameter of said fiber.  
     
     
       2. The apparatus of  claim 1  wherein said means comprises at least two of said movable arms defined by said front mask. 
     
     
       3. The apparatus of  claim 1  wherein said contact portion being near the distal end is located in an initial position relative to said one or more side walls and is moved away from said one or more side walls by said fiber when said fiber is inserted through said opening. 
     
     
       4. The apparatus of  claim 1  wherein said at least one side wall comprises at least two side walls, and 
       wherein said at least two side walls intersect each other and said fiber outer surface contacts each of said side walls and said means, and  
       said means comprises at least two of said movable arms, the contact portion of each arm for pressing the fiber toward opposite ones of said two side walls.  
     
     
       5. An optical fiber array apparatus comprising 
       a housing,  
       a front mask coupled to said housing and having a matrix of fiber seating openings therethrough, each said opening having one or more stationary side walls,  
       an unsheathed optical fiber portion extending through each of said openings and having an outer cylindrical side surface,  
       means for pressing said side surface into engagement with said one or more side walls,  
       wherein said front mask is primarily made of a first material,  
       said means includes an element made of a second flexible material forming a flexible side wall of each front mask opening,  
       said second material being more flexible than said first material.  
     
     
       6. The apparatus of  claim 5  wherein said fiber engages and flexes said element when said fiber is inserted into its respective opening. 
     
     
       7. The apparatus of  claim 6  wherein each of said elements are part of one of a plurality of elongated members. 
     
     
       8. The apparatus of  claim 7  wherein 
       said front mask comprises a plurality of elongated transverse slots and each of said openings opens into one of said slots, and each of said elongated members extends along one of said transverse slots.  
     
     
       9. An optical fiber array apparatus comprising 
       a housing,  
       a front mask coupled to said housing and having a matrix of fiber seating openings therethrough, each said opening having one or more side walls,  
       an unsheathed optical fiber portion extending through each of said openings and having an outer cylindrical side surface,  
       means for pressing said side surface into engagement with said one or more side walls,  
       said means includes an element of flexible material forming one side wall of each front mask opening,  
       wherein said fiber engages and flexes said element when said fiber is inserted into its respective opening,  
       wherein each of said elements are part of elongated members,  
       wherein said front mask comprises a plurality of elongated transverse slots and each of said openings opens into one of said slots, and  
       wherein each of said members is secured in one of said slots.  
     
     
       10. The apparatus of  claim 9  wherein 
       said front mask includes projections projecting partially into each of said slot and each projection being located between two of said openings for restricting the movement of respective members portions when a fiber is inserted through the respective opening therebetween.  
     
     
       11. The apparatus of  claim 1  wherein 
       said front mask has a region about each said opening with a first thickness in a direction parallel to the opening axis, and each said arm has at least a mid-section second thickness in a direction parallel to the opening axis which is less than said first thickness.  
     
     
       12. The apparatus of  claim 1  wherein 
       each said front mask opening is larger in cross section than the cross section of said fiber portion and bonding material substantially fills a void between the fiber portion and opening side wall.  
     
     
       13. The apparatus of  claim 5  wherein 
       each said front mask opening is larger in cross section than the cross section of said fiber portion and bonding material substantially fills a void between the fiber portion and opening side wall.